Coatings costs

A steady-state rocket-type combustion spray unit has been developed, called high velocity oxy fuel (HVOF), that creates a steady state, continuous, supersonic spray stream (1.2—3 mm dia) resembling a rocket motor exhaust. The portable device injects and accelerates the particles inside a barrel (rocket nozzle). It produces coating quaHty and particle velocities equal to the D-gun at 5—10 times the spray rate with significantly reduced coating costs. 

Therefore, for the same amount of appHed coating the volume of coating sold decreases. Because solvents are usually the lowest cost components of the coating, cost per unit volume increases. 

Surface preparation, always important in obtaining optimal coatings performance, is critical for marine coatings (see Metal surface treatments). Surface preparation usually comprises about half of the total coating costs, and if inadequate may be responsible for early coating failure. Proper surface preparation includes cleaning to remove contaminants and roughening the surface to faciUtate adhesion. 

Cathodic protection can be used as a renovation measure for steel-reinforced concrete structures (see Chapter 19). Although material costs of from 100 DM m" (particularly with preparation, erection, and spray coating costs) up to 300 DM m are quite high, they do not compare with the costs of demolition or partial replacement. ... 

All coatings cost money and a true appraisal of both the initial and maintenance costs is essential when specifying the protective scheme for a new structure. An example showing the comparative costs of galvanising and painting is given in Section 9.1. 

Metal powder can also be coated onto the workpiece. The 3M Company has developed a cold welding technique in which the workpiece, the metal powder, water, glass shot and additives are tumbled together in a barrel. Coatings are limited to ductile metals such as Cd, An, Sn, Pb, In, Ag, Cu, brass, and tin/lead solder the method is generally suitable only for small parts, and it doesn t produce a fine surfaced, cosmetic coating. Costs are comparable to those for electroplating with afterbake (Kirk-Othmer 1981). 

Combustion Chemical Vapor Deposition (CCVD) allows deposition of thin films that confer special electronic, catalytic, or optical properties, corrosion and oxidation resistance. The CCVD process is a novel, open-atmosphere process that is environmentally friendly and does not require expensive reaction/vacuum chambers. Often coatings are of equal or better quality than those obtained by vacuum-based methods. Coating costs are significantly lower than for more traditional processes such as Chemical Vapor Deposition (CVD) and Physical Vapor Deposition (PVD). Equally important, this novel technology can be implemented in a production-line environment, thus enabling uninterrupted processing. To date over 70 different inorganic materials have been deposited onto a variety... 

Approximate insulation and coating cost in 1978 were 50,000, but it cost 12,000 to repaint the tank. The payout for the insulation is about four years and, in addition, there is no need to repaint the tank every eight years as was previously done. 

Rehabilitation of internally corroded pipelines is somewhat more difficult to manage than external corrosion. Internally corroded pipes require cutting out and replacing the affected sections of the pipeline. Other methods of internal rehabilitation consist of pulled liners and epoxy flood coating. Cost estimates for these options can vary greatly and predominantly dependent on the extent of cleaning required to prepare the internal surface for coating. 

Epoxy coatings cost approximately 4.7-5.3/l while antifoulants are more expensive at 11.8-21.1/1. Environmental regulations have led to decreased amount of chemicals released from industrial installations along waterways, especially corrosives such as chlorine. The materials of construction for some water structures have also changed. Piers and docks are no longer constructed with wood, but instead are constructed with steel-reinforced concrete. To improve the lifespan of the structure and prevent corrosion of reinforcing steel, fusion-bonded epoxy-coated reinforcement or corrosion-inhibiting admixtures are sometimes utilized in the concrete mix. 

In order to evaluate the possible benefits due to the implementation of LPG tankers protections, besides safety and risk issues, it is important to consider also the economic aspects. Hence, in the followings an approach to identify and compare coating costs and benefits is described. These were assessed in the form of monetary quantities (by a common currency and on the base of a common temporal period) in order to determine if the LPG tanker coating involves an higher amount of costs or benefits by the comparison. 

Applying a coating to a LPG tank vehicle has a cost (CCF, coating cost per vehicle) which depends on chemical and physical characteristics of the insulating material. The FEM model previously quoted has demonstrated the effectiveness of different tjfpes of insulating material in avoiding BLEVE. The materials... 

To calculate the annual coating cost, the investment I is assumed equal to the value of CCF multiphed for the mnnber of vehicles belonging to the fleet for the LPG regional transport (Nfleet veh = 20) (3). 

Volume of pre-coat Mass of pre-coat Number of pre-coats per annum (14x340)/4 Pre-coat coat cost per annum (14x340x0.7 Ax350)/(4 xlOOO)... 

Approaches for mass production of catalyst layers, i.e. reducing the coating cost are rarely reported. A cheap possibility has been demonstrated by O CormeU et al. (2011) by screen printing in the application of micro-engineered fuel reformers for hydrogen production. Such a coating is shown in Fig. 2. 

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